Method for manufacturing reconstituted plant material

ABSTRACT

A method for manufacturing a reconstituted plant material includes the steps of extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion, separating the extract from the fibrous portion, forming a base sheet from the fibrous portion, and applying the extract to the base sheet. One or more additional steps may also be included, such as (but not limited to), combining a nicotine salt with the extract, extracting the extract with supercritical carbon dioxide, concentrating the extract to provide a concentrated extract, and/or combining a flavouring contained within a humectant or nicotine contained within a humectant with the extract.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

This application is a continuation of International Application No. PCT/EP2019/067304, filed Jun. 28, 2019; which claims benefit of GB Application No. 1810729.2, filed Jun. 29, 2018. This application is also a continuation of International Application No. PCT/EP2019/067307, filed Jun. 28, 2019; which claims benefit of GB Application No. 1810726.8, filed Jun. 29, 2018; and GB Application No. 1810727.6, filed Jun. 29, 2018. This application is also a continuation of International Application No. PCT/EP2019/067311, filed Jun. 28, 2019; which claims benefit of GB Application No. 1810728.4, filed Jun. 29, 2018. The entire contents of each of the above-referenced patents and patent applications are hereby expressly incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a method for reconstituting a plant material by a paper-making process, and a reconstituted tobacco product.

BACKGROUND

During the manufacturing process for tobacco products, such as cigarettes, tobacco waste is produced. The tobacco waste is typically in the form of tobacco dust, leaf or stem. The tobacco waste can be collected and processed to provide what is known as reconstituted tobacco, or “recon.”

Two distinct methods are most commonly employed to manufacture reconstituted tobacco, these are i) a paper-making process, and ii) slurry casting. The products that result from these distinct processes have notably different properties and characteristics. In particular, recon formed by the paper-making process typically has a reduced aroma/flavour and nicotine content in comparison to that formed by slurry casting.

In slurry casting the tobacco waste is milled to a fine powder and mixed with an aqueous solvent, typically water. The resultant slurry may undergo further milling to reduce the particle size of the tobacco material further. The slurry is then cast on a surface and dried to form a sheet. The dried sheet may be shredded to be used within various tobacco products, for example as a cigarette filler.

In the paper-making process the tobacco waste is mechanically beaten in the presence of an aqueous solvent to digest and process the tobacco into workable fibres to be made into a paper or web. Subsequently, water soluble compounds present in the tobacco are extracted into the aqueous solvent. The aqueous extract and insoluble fibrous portion are separated. The separated fibrous portion, which may also be described as a “pulp,” undergoes further processing to form a base sheet via a typical paper-making procedure. The aqueous extract is concentrated and then reapplied to the base sheet. The base sheet is then dried to form a paper.

The paper formed by the above process can be shredded and used as a filler within typical smoking articles such as cigarettes. Alternatively, it may be used as a wrapper to contain a tobacco rod.

Conventional reconstituted tobacco paper of this kind is generally not suitable for “heat-not-burn” (“HNB”) devices. For recon paper to be suitable for use within a HNB device a humectant must also be incorporated. Typical humectants include propylene glycol (“PG”) or vegetable glycerine (“VG”).

An HNB device heats the tobacco without burning it, i.e. it does not undergo combustion. The purpose of HNB devices is to avoid production, and subsequent inhalation, of harmful combustion products such as tar. By heating a humectant-impregnated recon paper the humectant is vaporised to form an aerosol, also referred to as a “vapour.” The aerosol may contain aroma/flavour compounds and/or nicotine derived from the recon paper. It is the aerosol which enables the user to simulate the act of smoking. WO 2017/051034 describes a reconstituted tobacco made by a paper making process which is suitable for an HNB device. In which, a humectant is added to the concentrated tobacco extract before application to the base-sheet to provide a humectant- impregnated recon paper.

Associated with the recon paper-making process is the loss of volatile compounds, such as nicotine and flavour compounds, from the tobacco during processing. This is linked with the large volumes of water used to digest and process the tobacco, and the high temperatures used to evaporate the water.

It is desirable to provide a safe and efficient way of increasing the nicotine and/or flavour content of recon tobacco made by a paper-making process. In particular it is desirable to provide a product that delivers an enhanced sensory experience to the consumer, which is consistent over multiple consumables.

Various efforts have been made to improve the nicotine content of recon tobacco made by a paper-making process. In U.S. Pat. No. 3,422,819, the nicotine content of a cigarette wrapper was increased by applying a solution of nicotine salt to a reconstituted tobacco sheet after manufacture of the paper. Alternatively, it is recognised in U.S. Pat. No. 3,422,819 that “the solution of nicotine salt may be added to the stock from which paper is formed.” The term “stock” refers to the mixture of pulp, fillers, other papermaking materials and water (see C. Biermann, Handbook of Pulping and Papermaking, 2^(nd) Edition). The stock, therefore, is the fibrous mixture post-extraction that enters the paper-making machine to be formed into a base sheet.

U.S. Pat. No. 3,861,400 describes a method of increasing the nicotine content of recon tobacco formed by a slurry casting method. This is achieved by the addition of specific polyuronic acid nicotine salt derivatives to a tobacco-water slurry. The products produced by slurry casting, and the method itself, are distinct to that of the recon paper-making process.

GB 1466912 describes an alternative method of increasing the nicotine content within recon tobacco paper. In which, roots of plants of the genus Nicotiana are grown in a specific culture medium. The grown roots are combined with tobacco solids to form a reconstituted tobacco base sheet. The spent culture medium, which includes nicotine exuded by the roots, is added to the tobacco soluble obtained in the production of the reconstituted tobacco. The tobacco soluble is concentrated and added to the base sheet.

CN 103468403 and CN 103462204 describe a method for extracting tobacco aroma compounds by conducting two separate extraction processes directly upon the tobacco raw material. This includes separate water extraction and supercritical carbon dioxide (scCO₂) extraction on the tobacco raw material. The two extracts are then combined and applied to the reconstituted tobacco.

Alternatively, CN 103783660 describes scCO₂ extraction on tobacco leaf fragments to extract flavour compounds. The flavour compounds are then separated, purified and reapplied to a reconstituted tobacco product by spraying or coating.

In the context of reconstituted tobacco suitable for use within a HNB device a number of documents describe that flavour additives may be optionally added to the humectant-impregnated recon paper, see for example, WO2017/051034, U.S. Pat. No. 5,325,877, U.S. Pat. No. 5,715,844 and US 2006/0021626. However, it is not specified within these documents how the flavour additives are added, nor at what stage in the paper-making process the flavour additives are added. Indeed, it is not recognised that flavor compounds are lost during the recon paper-making process. Therefore, it is apparent that the flavour additives are not intended to replace lost flavour during processing, but instead to impart a different taste experience to that of tobacco.

The present invention has been devised in light of the above considerations.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of preferred embodiments of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, provided by way of example only and in which:

FIG. 1 is an illustrative view of a manufacturing process for producing reconstituted tobacco for use in accordance with a first non-limiting embodiment of the present invention.

FIG. 2 is an illustrative view of a manufacturing process for producing reconstituted tobacco for use in accordance with a second non-limiting embodiment of the present invention.

FIG. 3 is an illustrative view of a manufacturing process for producing reconstituted tobacco for use in accordance with a third non-limiting embodiment of the present invention.

FIG. 4 is an illustrative view of a manufacturing process for producing reconstituted tobacco for use in accordance with a fourth non-limiting embodiment of the present invention.

SUMMARY OF CERTAIN NON-LIMITING EMBODIMENTS

First Mode of Invention: Addition of Flavour

According to a first aspect of the first mode of invention, there is provided a method for manufacturing a reconstituted plant material, the method comprising: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; concentrating the extract to provide a concentrated extract; forming a base sheet from the fibrous portion; combining a flavouring contained within a humectant with the concentrated extract; applying the concentrated extract to the base sheet.

Nicotine is a highly volatile compound and a controlled substance, consequently a number of handling difficulties exist during processing, as it is the subject of strict exposure limits. Similarly, many flavor compounds are volatile and are also the subject of exposure limits.

Advantageously, the pre-mixing of a flavouring and humectant prior to combining with the concentrated extract makes for a safer, efficient and reproducible delivery of flavouring to the concentrated extract. Additionally, by including a flavouring addition step in-situ to the paper-making process, flavour losses during processing are negated (e.g. losses through evaporation and high dilution). Furthermore, combining a mixture of flavouring and humectant to the concentrated extract ensures improved impregnation and uniform distribution of the flavouring and humectant throughout the final product. This provides a more consistent and improved sensory experience to the user.

Also, by providing the flavouring and humectant to the concentrated extract (which also contains other soluble compounds such as nicotine derived from the plant material) a homogeneous mixture of nicotine, humectant and flavour compounds is obtained. Consequently, a greater degree of intermingling of nicotine, humectant and flavour compounds is achieved in the recon paper to provide an improved sensory experience to the user.

During extraction the mixture of fibrous plant material and solvent are mechanically beaten to form a pulp. A pulp consists of lignocellulosic materials, e.g. plant fibres, which have been broken down physically and/or chemically such that discrete fibres are liberated and can be dispersed in solvent and reformed to form a web. Optionally, additional chemicals may be added to the mixture to aid digestion of the tobacco material and pulp formation. Suitable chemicals are known to those skilled in the art.

Suitable solvents are known to those skilled in the art. These include non-aqueous solvents and aqueous solvents. Examples of non-aqueous solvents includes but is not limited to alcohols, such as ethanol and propanol; acetone; acetonitrile; benzene; dichloromethane; ethyl acetate; hexane; and toluene.

Preferably, the solvent is an aqueous solvent. More preferably, the solvent is water. Optionally, the aqueous solvent may contain a co-solvent. Preferably, the co-solvent is water miscible. Examples of co-solvents are alcohols, acetone and acetonitrile.

Advantageously, water is a non-toxic and non-flammable solvent and is thus is easier to handle during processing. Furthermore, the risk of toxic solvent residues remaining in the final product is removed.

The temperature of the tobacco-water mixture during extraction is generally within the range 10-100° C. Preferably, the temperature is within the range 30-90° C. Particularly, preferred is the range 30-70° C.

The extraction time generally ranges from 30 minutes to 6 hours. Preferably, the extraction time is less than 4 hours, such as less than 3 hours, or such as less than 2 hours. Particularly, preferred is an extraction time less than 1 hour.

Preferably, the fibrous plant material is tobacco.

Advantageously, as the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a reconstituted plant material product having the inherent properties of tobacco, for example the texture, aroma and nicotine content.

Preferably, the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder and/or tobacco dust.

Advantageously, these forms of tobacco are typically derived as waste from tobacco processing, thus by utilising this “waste” to form the product of the invention the amount of unused tobacco material is minimised.

Preferably, the flavouring is selected from Mild Menthol, Mixed Berry, Cool Menthol, Peach, Cream Cake, Melon Medley, Apple, Shisha Grape, Virginia Tobacco, and American Red Blend.

Advantageously, these flavourings provide the user with a satisfactory flavour “hit” and additionally provide an improved sensory experience to the user.

Preferably, the humectant is a polyol.

Advantageously, good dispersion of flavouring in the humectant is achieved when the humectant is a polyol.

Preferably, the polyol is propylene glycol or vegetable glycerine or a combination thereof.

Advantageously, both propylene glycol and vegetable glycerine exhibit minimal toxicity. Furthermore, they impart a sweet taste that is satisfactory to the user.

Preferably, the flavouring content contained within the humectant is within the range 1 to 95 wt % based on the total weight of flavouring and humectant, such as 1 to 50 wt %, such as 1 to 25 wt %, such as 1 to 15 wt %.

Advantageously, this provides sufficient dilution of flavouring with humectant to provide safer handling of flavouring during processing. Also, such a combination allows for good dispersion of flavouring within the humectant.

The method according to the first aspect of the first mode of invention may further comprise a step of making an HNB consumable.

According to a second aspect of the first mode of invention, there is provided a reconstituted tobacco product for an HNB device produced by a process according to the first aspect of the first mode of invention comprising: a humectant; and a flavouring; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the flavouring content is 2 to 25% by weight of the reconstituted tobacco product.

Advantageously, by increasing the minimum amount of flavouring present in the reconstituted tobacco product the vapour produced, when in use, will have a higher flavour content; thus a stronger flavor “hit” may be experienced by the user. In addition, the size of the product itself may be decreased, in comparison to known recon paper products, without any reduction in the total amount of flavour delivered to the user per consumable.

Preferably, the humectant is a polyol.

Preferably, the polyol is propylene glycol or vegetable glycerin or combinations thereof.

The advantages of using a polyol humectant, and in particular, propylene glycol and vegetable glycerine is as described for the first aspect of the first mode of invention.

Preferably, the flavouring is selected from Mild Menthol, Mixed Berry, Cool Menthol, Peach, Cream Cake, Melon Medley, Apple, Shisha Grape, Virginia Tobacco, and American Red Blend.

The advantages of using flavourings from this selection is as described for the first aspect of the first mode of invention.

The flavouring content of the reconstituted tobacco product may have a lower limit of at least 2 wt % of the weight of the reconstituted tobacco product, such as at least 3 wt %, such as at least 4 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %.

The flavouring content of the reconstituted tobacco product may have an upper limit of at most 25 wt %, such as at most 20 wt %, such as at most 15 wt %, or such as at most 10 wt %.

Preferably, the flavouring content is 5 to 25 wt % of the reconstituted tobacco product, such as 10 to 25 wt %, such as 15 to 25 wt %

Advantageously, a reconstituted tobacco product with flavour content higher than achieved using typical processes is provided. This enables the amount of flavour to be tailored to suit the user's requirements.

The humectant content of the reconstituted tobacco product may have a lower limit of at least 1% by weight of the reconstituted tobacco, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the reconstituted tobacco product may have an upper limit of at most 50% by weight of the reconstituted tobacco, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the reconstituted tobacco product, such as 1 to 20 wt %.

Advantageously, an amount of humectant within this range provides the user with a satisfactory “hit” of vapour and additionally provides the user with an improved sensory experience.

According to a third aspect of the first mode of invention, there is provided use of the reconstituted tobacco product according to the second aspect of the first mode of invention in a HNB device.

According to a fourth aspect of the first mode of invention, there is provided an HNB consumable comprising the reconstituted tobacco product according to the second aspect of first mode of the invention.

According to a fifth aspect of the first mode of invention, there is provided an HNB system comprising an HNB consumable according to the fourth aspect of the first mode of invention, and an HNB device.

According to a sixth aspect of the first mode of invention, there is provided a reconstituted tobacco product comprising: a humectant; and a flavouring; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the flavouring content is 2 to 25% by weight of the reconstituted tobacco product.

Second Mode of Invention: Addition of Nicotine

According to a first aspect of the second mode of invention, there is provided a method for manufacturing a reconstituted plant material, the method comprising: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; concentrating the extract to provide a concentrated extract; forming a base sheet from the fibrous portion; combining nicotine contained within a humectant to the concentrated extract; applying the concentrated extract to the base sheet.

Nicotine is a highly volatile compound and a controlled substance, consequently a number of handling difficulties exist during processing, as it is the subject of strict exposure limits. Similarly, many flavor compounds are volatile and are also the subject of exposure limits.

Advantageously, the pre-mixing of nicotine and humectant prior to combining with the concentrated extract makes for a safer, efficient and reproducible delivery of nicotine to the concentrated extract. Additionally, by including a nicotine addition step in-situ to the paper-making process, nicotine losses during processing are negated (e.g. losses through evaporation and high dilution). Furthermore, combining a mixture of nicotine and humectant to the concentrated extract ensures improved impregnation and uniform distribution of the nicotine and humectant throughout the final product. This provides a more consistent and improved sensory experience to the user.

Also, by providing the nicotine and humectant to the concentrated extract (which also contains other soluble compounds such as flavour compounds derived from the plant material) a homogeneous mixture of nicotine, humectant and flavour compounds is obtained. Consequently, a greater degree of intermingling of nicotine, humectant and flavour compounds is achieved in the recon paper to provide an improved sensory experience to the user.

During extraction the mixture of fibrous plant material and solvent are mechanically beaten to form a pulp. A pulp consists of lignocellulosic materials, e.g. plant fibres, which have been broken down physically and/or chemically such that discrete fibres are liberated and can be dispersed in solvent and reformed to form a web. Optionally, additional chemicals may be added to the mixture to aid digestion of the tobacco material and pulp formation. Suitable chemicals are known to those skilled in the art.

Suitable solvents are known to those skilled in the art. These include non-aqueous solvents and aqueous solvents. Examples of non-aqueous solvents includes but is not limited to alcohols, such as ethanol and propanol; acetone; acetonitrile; benzene; dichloromethane; ethyl acetate; hexane; and toluene.

Preferably, the solvent is an aqueous solvent. More preferably, the solvent is water. Optionally, the aqueous solvent may contain a co-solvent. Preferably, the co-solvent is water miscible. Examples of co-solvents are alcohols, acetone and acetonitrile.

Advantageously, water is a non-toxic and non-flammable solvent and is thus is easier to handle during processing. Furthermore, the risk of toxic solvent residues remaining in the final product is removed.

The temperature of the tobacco-water mixture during extraction is generally within the range 10-100° C. Preferably, the temperature is within the range 30-90° C. Particularly, preferred is the range 30-70° C.

The extraction time generally ranges from 30 minutes to 6 hours. Preferably, the extraction time is less than 4 hours, such as less than 3 hours, or such as less than 2 hours. Particularly, preferred is an extraction time less than 1 hour.

Preferably, the fibrous plant material is tobacco.

Advantageously, as the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a reconstituted plant material product having the inherent properties of tobacco, for example the texture, aroma and nicotine content.

Preferably, the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder and/or tobacco dust.

Advantageously, these forms of tobacco are typically derived as waste from tobacco processing, thus by utilising this “waste” to form the product of the invention the amount of unused tobacco material is minimised.

Preferably, the humectant is a polyol.

Advantageously, good dispersion of nicotine in the humectant is achieved when the humectant is a polyol.

Preferably, the polyol is propylene glycol or vegetable glycerine or a combination thereof.

Advantageously, both propylene glycol and vegetable glycerine exhibit minimal toxicity. Furthermore, they impart a sweet taste that is satisfactory to the user.

Preferably, the nicotine content contained within the humectant is within the range 1 to 95 wt % based on the total weight of nicotine and humectant, such as 1 to 50 wt %, such as 1 to 25 wt %, such as 1 to 15 wt %.

Advantageously, this provides sufficient dilution of nicotine with humectant to provide safer handling of nicotine during processing. Also, such a combination allows for good dispersion of nicotine within the humectant.

The method according the first aspect of the second mode of invention may further comprise a step of making an HNB consumable.

According to a second aspect of the second mode of the invention, there is provided a reconstituted tobacco product for an HNB device produced by a process according the first aspect of the second mode of invention comprising: a humectant; and nicotine; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

Advantageously, by increasing the minimum amount of nicotine present in the reconstituted tobacco product the vapour produced, when in use, will have a higher nicotine content; thus a stronger nicotine “hit” may be experienced by the user. In addition, the size of the product itself may be decreased, in comparison to known recon paper products, without any reduction in the total amount of nicotine delivered to the user per consumable.

Preferably, the humectant is a polyol.

Preferably, the polyol is propylene glycol or vegetable glycerin or combinations thereof.

The advantages of using a polyol humectant, and in particular, propylene glycol and vegetable glycerine is as described for the first aspect of the second mode of invention

The nicotine content of the reconstituted tobacco product may have a lower limit of at least 2 wt % of the weight of the reconstituted tobacco product, such as at least 3 wt %, such as at least 4 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %.

The nicotine content of the reconstituted tobacco product may have an upper limit of at most 25 wt %, such as at most 20 wt %, such as at most 15 wt %, or such as at most 10 wt %.

Preferably, the nicotine content is 5 to 25 wt % of the reconstituted tobacco product such as 10 to 25 wt %, such as 15 to 25 wt %.

Advantageously, a reconstituted tobacco product with nicotine content higher than achieved using typical processes is provided. This enables the amount of nicotine to be tailored to suit the user's requirements.

The humectant content of the reconstituted tobacco product may have a lower limit of at least 1% by weight of the reconstituted tobacco, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the reconstituted tobacco product may have an upper limit of at most 50% by weight of the reconstituted tobacco, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the reconstituted tobacco product, such as 1 to 20 wt %.

Advantageously, an amount of humectant within this range provides the user with a satisfactory “hit” of vapour and additionally provides the user with an improved sensory experience.

According to a third aspect of the second mode of invention, there is provided use of the reconstituted tobacco product according to the second aspect of the second mode of invention in a HNB device.

According to a fourth aspect of the second mode of invention, there is provided an HNB consumable comprising the reconstituted tobacco product according to the second aspect of the second mode of invention.

According to a fifth aspect of the second mode of invention, there is provided an HNB system comprising an HNB consumable according to the fourth aspect of the second mode of the invention, and an HNB device.

According to a sixth aspect of the second mode of invention, there is provided reconstituted tobacco product comprising: a humectant; and nicotine; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

Third Mode of the Invention

According to a first aspect of the third mode of the invention, there is provided a method for manufacturing a reconstituted plant material, the method comprising: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; forming a base sheet from the fibrous portion; combining a nicotine salt with the extract; applying the extract to the base sheet.

Nicotine is a highly volatile compound and a controlled substance, consequently a number of handling difficulties exist during processing, as it is the subject of strict exposure limits. Similarly, many flavour compounds are volatile and are also the subject of exposure limits.

Advantageously, nicotine salts exhibit lower volatility and higher stability than nicotine, therefore provide a safer and more convenient means of handling during processing. Additionally, by including a nicotine salt-addition step in-situ to the paper-making process, nicotine losses during processing are negated (e.g. losses through evaporation and high dilution). Furthermore, combining a nicotine salt with the extract ensures improved impregnation and uniform distribution of the nicotine salt throughout the final product. This provides a more consistent and improved sensory experience to the user.

Also, by providing the nicotine salt to the extract (which also contains other soluble compounds such as flavour compounds derived from the plant material) a homogeneous mixture of nicotine salt and flavour compounds is obtained. Consequently, a greater degree of intermingling of nicotine salt and flavour compounds is achieved in the recon paper to provide an improved sensory experience to the user.

During extraction the mixture of fibrous plant material and solvent are mechanically beaten to form a pulp. A pulp consists of lignocellulosic materials, e.g. plant fibres, which have been broken down physically and/or chemically such that discrete fibres are liberated and can be dispersed in solvent and reformed to form a web. Optionally, additional chemicals may be added to the mixture to aid digestion of the tobacco material and pulp formation. Suitable chemicals are known to those skilled in the art.

Suitable solvents are known to those skilled in the art. These include non-aqueous solvents and aqueous solvents. Examples of non-aqueous solvents includes but is not limited to alcohols, such as ethanol and propanol; acetone; acetonitrile; benzene; dichloromethane; ethyl acetate; hexane; and toluene.

Preferably, the solvent is an aqueous solvent. More preferably, the solvent is water. Optionally, the aqueous solvent may contain a co-solvent. Preferably, the co-solvent is water miscible. Examples of co-solvents are alcohols, acetone and acetonitrile.

Advantageously, water is a non-toxic and non-flammable solvent and is thus is easier to handle during processing. Furthermore, the risk of toxic solvent residues remaining in the final product is removed.

The temperature of the tobacco-water mixture during extraction is generally within the range 10-100° C. Preferably, the temperature is within the range 30-90° C. Particularly, preferred is the range 30-70° C.

The extraction time generally ranges from 30 minutes to 6 hours. Preferably, the extraction time is less than 4 hours, such as less than 3 hours, or such as less than 2 hours. Particularly, preferred is an extraction time less than 1 hour.

Preferably, the method further comprises a step of concentrating the extract to provide a concentrated extract, before applying the extract to the base sheet.

Advantageously, this minimises the drying time of the base sheet and improves the process efficiency of applying the extract to the paper.

Preferably, the nicotine salt is combined with the concentrated extract.

Advantageously, the combination of the nicotine salt with the concentrated extract minimises losses of the nicotine salt through decomposition and/or evaporation during concentration of the extract.

Preferably, the fibrous plant material is tobacco.

Advantageously, as the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a reconstituted plant material product having the inherent properties of tobacco, for example the texture, aroma and nicotine content.

Preferably, the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder and/or tobacco dust.

Advantageously, these forms of tobacco are typically derived as waste from tobacco processing, thus by utilising this “waste” to form the product of the invention the amount of unused tobacco material is minimised.

Preferably, the nicotine salt is selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof.

Advantageously, these salts provide the user with a satisfactory nicotine “hit” and additionally provide an improved sensory experience to the user.

Preferably, the nicotine salt is provided as an aqueous solution.

Advantageously, the non-toxicity and non-flammability of water minimises handling risks during processing. Furthermore, the “premixing” of the nicotine salt with a solvent prior to combination with the extract, improves the homogeneous nature of the nicotine salt and extract mixture.

Preferably, the aqueous solution of nicotine salt includes a co-solvent, for example alcohols, acetone or acetonitrile.

Advantageously, the presence of a co-solvent may improve the solubility of the nicotine salt in solution. This may help improve the homogeneity of the mixture of the nicotine salt solution and the extract.

The method according to the first aspect of the third mode of invention may further comprise a step of making an HNB consumable.

According to a second aspect of the third mode of invention, there is provided a reconstituted tobacco product for an HNB device produced by a process according to the first aspect of the third mode of invention comprising: a nicotine salt selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof, wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

Advantageously, by increasing the minimum amount of nicotine present in the reconstituted tobacco product a stronger nicotine “hit” may be experienced by the user. In addition, the size of the product itself may be decreased, in comparison to known recon paper products, without any reduction in the total amount of nicotine delivered to the user per consumable.

The nicotine content of the reconstituted tobacco product may have a lower limit of at least 2 wt % of the weight of the reconstituted tobacco product, such as at least 3 wt %, such as at least 4 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %.

The nicotine content of the reconstituted tobacco product may have an upper limit of at most 25 wt %, such as at most 20 wt %, such as at most 15 wt %, or such as at most 10 wt %.

Preferably, the nicotine content is 5 to 25% by weight of the reconstituted tobacco product, such as 10 to 25 wt %, such as 15 to 25 wt %.

Advantageously, a reconstituted tobacco product with nicotine content higher than achieved using typical processes is provided. This enables the amount of nicotine to be tailored to suit the user's requirements.

According to a third aspect of the third mode of invention, there is provided use of the reconstituted tobacco product according to the second aspect of the third mode of invention in a HNB device.

According to a fourth aspect of the third mode of invention, there is provided an HNB consumable comprising the reconstituted tobacco product according to the second aspect of the third mode of invention.

According to a fifth aspect of the third mode of invention, there is provided an HNB system comprising an HNB consumable according to the fourth aspect of the third mode of invention, and an HNB device.

According to a sixth aspect of the third mode of invention, there is provided a provided a reconstituted tobacco product comprising: a nicotine salt selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof, wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

Fourth Mode of Invention

According to a first aspect of the fourth mode of invention, there is provided a method for manufacturing a reconstituted plant material, the method comprising: extracting a fibrous plant material with a liquid solvent to provide a first extract and a fibrous portion; separating the first extract from the fibrous portion; extracting the first extract with supercritical carbon dioxide to provide a second extract; forming a base sheet from the fibrous portion; applying the second extract to the base sheet.

Advantageously, by carrying out supercritical extraction on the first extract flavour compounds are recovered and retained. This prevents loss of flavour compounds by evaporation or decomposition during processing of the first extract. Furthermore, supercritical extraction on a liquid feedstock may provide a continuous process that can be automated, which may provide lower operating costs. Such continuous processes are more difficult to achieve when the feedstock is solid (e.g. tobacco raw material). Also, by carrying out supercritical extraction on the first extract, rather than directly upon the fibrous plant material itself, the supercritical extraction of unwanted compounds is avoided. Example unwanted compounds include those that are insoluble in the liquid solvent (i.e. not extracted into the liquid solvent), thus their removal by a direct supercritical CO₂ extraction of the plant material would be unnecessary.

During liquid extraction the mixture of fibrous plant material and solvent are mechanically beaten to form a pulp. A pulp consists of lignocellulosic materials, e.g. plant fibres, which have been broken down physically and/or chemically such that discrete fibres are liberated and can be dispersed in solvent and reformed to form a web. Optionally, additional chemicals may be added to the mixture to aid digestion of the tobacco material and pulp formation. Suitable chemicals are known to those skilled in the art.

Preferably the method further comprises the steps of concentrating the first extract to provide a concentrated extract, and combining the second extract with the concentrated extract before applying the second extract to the base sheet.

Advantageously, by combining the second extract to the concentrated extract (which also contains other soluble compounds such as nicotine derived from the plant material) a homogeneous mixture of nicotine and flavour compounds is obtained. Consequently, a greater degree of intermingling of nicotine and flavour compounds is achieved in the recon paper to provide an improved sensory experience to the user. A further advantage is improved impregnation and uniform distribution of flavouring throughout the final product.

The critical point of carbon dioxide has a critical temperature of 31° C. and critical pressure of 74 bar.

The conditions for supercritical extraction are easily tuned by adjusting temperature and pressure. Consequently, a wide range of different flavour compounds can be extracted. Furthermore, the conditions may be tuned to selectively extract certain compounds. This allows the flavour of the final product to be tailored as desired.

Suitable liquid solvents are known to those skilled in the art. These include non-aqueous solvents and aqueous solvents. Examples of non-aqueous solvents includes but is not limited to alcohols, such as ethanol and propanol; acetone; acetonitrile; benzene; dichloromethane; ethyl acetate; hexane; and toluene.

Preferably, the liquid solvent is an aqueous solvent. More preferably, the liquid solvent is water. Optionally, the aqueous solvent may contain a co-solvent. Preferably, the co-solvent is water miscible. Examples of co-solvents are alcohols, acetone and acetonitrile.

The temperature of the tobacco-water mixture during liquid extraction is generally within the range 35-100° C. Preferably, the temperature is within the range 30-90° C. Particularly, preferred is the range 30-70° C.

The liquid extraction time generally ranges from 30 minutes to 6 hours. Preferably, the liquid extraction time is less than 4 hours, such as less than 3 hours, or such as less than 2 hours.

Particularly, preferred is a liquid extraction time less than 1 hour.

Preferably, the fibrous plant material is tobacco.

Advantageously, as the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a reconstituted plant material product having the inherent properties of tobacco, for example the texture, aroma and nicotine content.

Preferably, the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder and/or tobacco dust.

Advantageously, these forms of tobacco are typically derived as waste from tobacco processing, thus by utilising this “waste” to form the product of the invention the amount of unused tobacco material is minimised.

Preferably, the supercritical carbon dioxide extraction pressure is within the range 74 to 350 bar, such as 74 to 200 bar.

Advantageously, these pressures provide sufficient extraction of the compounds of interest whilst providing a process with good economic efficiency.

Preferably, the supercritical carbon dioxide extraction temperature is within the range 31° C. to 100° C., such as 40° C. to 80° C. and 40° C. to 60° C.

Advantageously, these temperatures provide sufficient extraction of the compounds of interest whilst providing a process with good economic efficiency. Additionally, the use of extraction temperatures lower than 100° C. improves the economic efficiency by providing milder reaction conditions.

Preferably, the supercritical carbon dioxide contains 1 to 20 mol % of an entrainer. An entrainer is used to modify the solvation characteristics of supercritical carbon dioxide. Examples of entrainers include alcohols, such as methanol and ethanol.

Advantageously, the presence of an entrainer in this amount enhances the solvent power of the supercritical carbon dioxide towards the compounds of interest.

The supercritical extraction may be carried out in a countercurrent column or cocurrent column.

Preferably, the supercritical extraction is countercurrent supercritical carbon dioxide extraction.

Advantageously, the use of countercurrent extraction improves extraction of compounds into the supercritical carbon dioxide. Also, countercurrent extraction reduces the amount of supercritical carbon dioxide required for extraction.

The method according to the first aspect of the fourth mode of invention may further comprise a step of making an HNB consumable.

According to a second aspect of the fourth mode of invention there is provided a reconstituted tobacco product produced by a process according to the first aspect of the fourth mode of invention.

According to a third aspect of the fourth mode of invention, there is provided use of the reconstituted tobacco product according to the second aspect of the fourth mode of invention in a HNB device.

According to a fourth aspect of the fourth mode of invention, there is provided an HNB consumable comprising the reconstituted tobacco product according to the second aspect of the fourth mode of invention.

According to a fifth aspect of the fourth mode of invention, there is provided an HNB system comprising an HNB consumable according to the fourth aspect of the fourth mode of invention, and an HNB device.

DETAILED DESCRIPTION

Before the invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described, and as such may, of course, vary. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and not intended to be limiting, since the scope of the present invention will be limited by the appended claims.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs or as determined by the context in which such terms are used. Although any methods and materials similar or equivalent to those described herein can also be used in the practise or testing of the present invention, a limited number of exemplary methods and materials are described herein.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present patent application.

First Mode of Invention: Addition of Flavour

The present invention provides a method for manufacturing reconstituted plant material comprising the following steps: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; concentrating the extract to provide a concentrated extract; forming a base sheet from the fibrous portion; combining a flavouring contained within a humectant with the concentrated extract; applying the concentrated extract to the base sheet.

FIG. 1 illustrates the preferred embodiment of the first mode of the invention, wherein the fibrous plant material is tobacco. With reference to FIG. 1 this embodiment is described in detail below.

Any suitable plant material that requires reconstituting as a paper, wherein the loss of volatile compounds during processing (such as alkaloid derivatives or flavour compounds) is detrimental to the final product, may be used in the present invention.

Preferably, the plant material is tobacco. Any type of tobacco may be used in the present invention.

This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers. In particular, tobacco waste is used, tobacco waste is typically in the form of tobacco leaf, stem, powder or dust.

Initially, the tobacco material is added to an aqueous solvent to extract the water soluble tobacco components 1. Prior to this the tobacco material may be optionally grinded, threshed or cut.

Typically, the amount of aqueous solvent to tobacco material is within the range 75-99 wt % of the total weight of the tobacco-aqueous solvent mixture.

The tobacco-aqueous solvent mixture is mechanically beaten during extraction 1 in order to create a pulp.

After extraction 1, the fibrous portion and aqueous extract are separated, step 2. This may be achieved by centrifugation, filtration, mechanical pressing or any other methods known in the paper-making industry.

The separated fibrous portion 6 is further refined to form a refined pulp suitable for entry into the paper-making machine 7. Typical pulp refiners include disk refiners and conical refiners. The refined pulp is then properly slurried and treated to remove contaminants and entrained air.

The refined pulp slurry is applied to a paper-making machine. The paper-making machine comprises a forming section 8, drainage section, pressing section 9 and a drying section 11. In the forming section 8 the slurry of refined pulp 7 is applied to a wire sheet, also known as a “forming fabric,” to form a web. The wire permits draining of excess water from the web by gravity to form a sheet. Alternatively, suction equipment may also be used permit drainage. Excess water is further removed by means of a press 9. The press is a typically a pair of squeeze or wringer rolls designed to remove water mechanically and smooth and compress the sheet formed. Drying 11 of the sheet is typically facilitated by drum dryers.

The aqueous extract 3 is concentrated 4. This is achieved by any conventional means, for example by applying thermal energy and/or evaporation under vacuum.

A flavouring contained within a humectant is combined with the concentrated aqueous extract in step 5.

The concentrated aqueous extract 5 is preferably applied to the sheet after the sheet has proceeded through the pressing section, and before the sheet has proceeded through the drying section of the paper-making machine, step 10. The concentrated aqueous extract 5 may be applied to the sheet using spray coating, wetted rollers or any other method suitable in the art. Following this the sheet is dried 11.

The present invention also provides a reconstituted tobacco product for a HNB device produced by a process according to the method of invention comprising: a humectant; a flavouring; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the flavouring content is 2 to 25% by weight of the reconstituted tobacco product.

The reconstituted tobacco product of the present invention may be used as a tobacco rod, suitable to be ensleeved by a wrapper such as a cigarette paper 12. The reconstituted tobacco product may be shredded to form a tobacco rod. Alternatively, the reconstituted tobacco product may be wrapped or folded to form a tobacco rod 12.

The reconstituted tobacco product of the present invention may also be used as a consumable, or part of a consumable, for an HNB device. It is a reconstituted tobacco product for use in an HNB device.

Second Mode of Invention: Addition of Nicotine

The present invention provides a method for manufacturing reconstituted plant material comprising the following steps: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; concentrating the extract to provide a concentrated extract; forming a base sheet from the fibrous portion; combining nicotine contained within a humectant with the concentrated extract; applying the concentrated extract to the base sheet.

FIG. 2 illustrates the preferred embodiment of the second mode of invention, wherein the fibrous plant material is tobacco. With reference to FIG. 2 this embodiment is described in detail below.

Any suitable plant material that requires reconstituting as a paper, wherein the loss of volatile compounds during processing (such as alkaloid derivatives or flavour compounds) is detrimental to the final product, may be used in the present invention.

Preferably, the plant material is tobacco. Any type of tobacco may be used in the present invention. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers. In particular, tobacco waste is used, tobacco waste is typically in the form of tobacco leaf, stem, powder or dust.

Initially, the tobacco material is added to an aqueous solvent to extract the water soluble tobacco components 1′. Prior to this the tobacco material may be optionally grinded, threshed or cut.

Typically, the amount of aqueous solvent to tobacco material is within the range 75-99 wt % of the total weight of the tobacco-aqueous solvent mixture.

The tobacco-aqueous solvent mixture is mechanically beaten during extraction 1′ in order to create a pulp.

After extraction 1′, the fibrous portion and aqueous extract are separated, step 2′. This may be achieved by centrifugation, filtration, mechanical pressing or any other methods known in the paper-making industry.

The separated fibrous portion 6′ is further refined to form a refined pulp suitable for entry into the paper-making machine 7′. Typical pulp refiners include disk refiners and conical refiners. The refined pulp is then properly slurried and treated to remove contaminants and entrained air.

The refined pulp slurry is applied to a paper-making machine 8′. The paper-making machine comprises a forming section 8′, drainage section, pressing section 9′ and a drying section 11′. In the forming section 8′ the slurry of refined pulp 7′ is applied to a wire sheet, also known as a “forming fabric,” to form a web. The wire permits draining of excess water from the web by gravity to form a sheet. Alternatively, suction equipment may also be used permit drainage. Excess water is further removed by means of a press 9′. The press is a typically a pair of squeeze or wringer rolls designed to remove water mechanically and smooth and compress the sheet formed. Drying 11′ of the sheet is typically facilitated by drum dryers.

The aqueous extract 3′ is concentrated 4′. This is achieved by any conventional means, for example by applying thermal energy and/or evaporation under vacuum.

Nicotine contained within a humectant is combined with the concentrated aqueous extract in step 5′.

The concentrated aqueous extract 5′ is preferably applied to the sheet after the sheet has proceeded through the pressing section, and before the sheet has proceeded through the drying section of the paper-making machine, step 10′. The concentrated aqueous extract 5′ may be applied to the sheet using spray coating, wetted rollers or any other method suitable in the art. Following this the sheet is dried 11′.

The present invention also provides a reconstituted tobacco product for a HNB device produced by a process according to method of invention comprising: a humectant; nicotine; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product, and wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

The reconstituted tobacco product of the present invention may be used as a tobacco rod, suitable to be ensleeved by a wrapper such as a cigarette paper 12′. The reconstituted tobacco product may be shredded to form a tobacco rod. Alternatively, the reconstituted tobacco product may be wrapped or folded to form a tobacco rod 12′.

The reconstituted tobacco product of the present invention may also be used as a consumable, or part of a consumable, for an HNB device. It is a reconstituted tobacco product for use in an HnB device.

Third Mode of the Invention

The present invention provides a method for manufacturing reconstituted plant material comprising the following steps: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; forming a base sheet from the fibrous portion; combining a nicotine salt with the extract; applying the extract to the base sheet.

FIG. 3 illustrates one embodiment of the invention, wherein the fibrous plant material is tobacco, and wherein the nicotine salt is combined with a concentrated aqueous extract. With reference to FIG. 3 this embodiment is described in detail below.

Any suitable plant material that requires reconstituting as a paper, wherein the loss of volatile compounds during processing (such as alkaloid derivatives or flavour compounds) is detrimental to the final product, may be used in the present invention.

Preferably, the plant material is tobacco. Any type of tobacco may be used in the present invention. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers. In particular, tobacco waste is used, tobacco waste is typically in the form of tobacco leaf, stem, powder or dust.

Initially, the tobacco material is added to an aqueous solvent to extract the water soluble tobacco components 1. Prior to this the tobacco material may be optionally grinded, threshed or cut.

Typically, the amount of aqueous solvent to tobacco material is within the range 75-99 wt % of the total weight of the tobacco-aqueous solvent mixture.

The tobacco-aqueous solvent mixture is mechanically beaten during extraction 1 in order to create a pulp.

After extraction 1, the fibrous portion and aqueous extract are separated, step 2. This may be achieved by centrifugation, filtration, mechanical pressing or any other methods known in the paper-making industry.

The separated fibrous portion 6 is further refined to form a refined pulp suitable for entry into the paper-making machine 7. Typical pulp refiners include disk refiners and conical refiners. The refined pulp is then properly slurried and treated to remove contaminants and entrained air.

The refined pulp slurry is applied to a paper-making machine 8. The paper-making machine comprises a forming section 8, drainage section, pressing section 9 and a drying section 11. In the forming section 8 the slurry of refined pulp 7 is applied to a wire sheet, also known as a “forming fabric,” to form a web. The wire permits draining of excess water from the web by gravity to form a sheet. Alternatively, suction equipment may also be used permit drainage. Excess water is further removed by means of a press 9. The press is a typically a pair of squeeze or wringer rolls designed to remove water mechanically and smooth and compress the sheet formed. Drying 11 of the sheet is typically facilitated by drum dryers.

The aqueous extract 3 is concentrated 4. This is achieved by any conventional means, for example by applying thermal energy and/or evaporation under vacuum.

A nicotine salt is combined with the concentrated aqueous extract in step 5. The nicotine salt may be combined in its pure form. The nicotine salt may be a solid or a liquid.

Alternatively, the nicotine salt may be an aqueous solution. The amount of nicotine combined may be tailored to the content required in the final product.

The concentrated aqueous extract 5 is preferably applied to the sheet after the sheet has proceeded through the pressing section, and before the sheet has proceeded through the drying section of the paper-making machine, step 10. The concentrated aqueous extract 5 may be applied to the sheet using spray coating, wetted rollers or any other method suitable in the art. Following this the sheet is dried 11.

The present invention also provides a reconstituted tobacco product for an HNB device produced by a process according to the method of the invention, wherein the reconstituted tobacco product comprises: a nicotine salt selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof, and wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.

The reconstituted tobacco product of the present invention may be used as a tobacco rod, suitable to be ensleeved by a wrapper such as a cigarette paper 12. The reconstituted tobacco product may be shredded to form a tobacco rod. Alternatively, the reconstituted tobacco product may be wrapped or folded to form a tobacco rod 12.

The reconstituted tobacco product of the present invention may also be used as a consumable, or part of a consumable, for an HNB device. It is a reconstituted tobacco product for use in an HNB device.

Fourth Mode of the Invention

The present invention provides a method for manufacturing reconstituted plant material comprising the following steps: extracting a fibrous plant material with a liquid solvent to provide a first extract and a fibrous portion; separating the first extract from the fibrous portion; extracting the first extract with supercritical carbon dioxide to provide a second extract; forming a base sheet from the fibrous portion; applying the second extract to the base sheet.

FIG. 4 illustrates the preferred embodiment of the invention, wherein the fibrous plant material is tobacco. With reference to FIG. 4 this embodiment is described in detail below.

Any suitable plant material that requires reconstituting as a paper, wherein the loss of volatile compounds during processing (such as alkaloid derivatives or flavour compounds) is detrimental to the final product, may be used in the present invention.

Preferably, the plant material is tobacco. Any type of tobacco may be used in the present invention. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers. In particular, tobacco waste is used, tobacco waste is typically in the form of tobacco leaf, stem, powder or dust.

Initially, the tobacco material is added to an aqueous solvent to extract the water soluble tobacco components 1. Prior to this the tobacco material may be optionally grinded, threshed or cut.

Typically, the amount of aqueous solvent to tobacco material is within the range 75-99 wt % of the total weight of the tobacco-aqueous solvent mixture.

The tobacco-aqueous solvent mixture is mechanically beaten during extraction 1 in order to create a pulp.

After extraction 1, the fibrous portion and aqueous extract are separated, step 2. This may be achieved by centrifugation, filtration, mechanical pressing or any other methods known in the paper-making industry.

The separated fibrous portion 9 is further refined to form a refined pulp suitable for entry into the paper-making machine 10. Typical pulp refiners include disk refiners and conical refiners. The refined pulp is then properly slurried and treated to remove contaminants and entrained air.

The refined pulp slurry is applied to a paper-making machine 11. The paper-making machine comprises a forming section 11, drainage section, pressing section 12 and a drying section 14. In the forming section 11 the slurry of refined pulp 10 is applied to a wire sheet, also known as a “forming fabric,” to form a web. The wire permits draining of excess water from the web by gravity to form a sheet. Alternatively, suction equipment may also be used permit drainage. Excess water is further removed by means of a press 12. The press is a typically a pair of squeeze or wringer rolls designed to remove water mechanically and smooth and compress the sheet formed. Drying 11 of the sheet is typically facilitated by drum dryers.

The aqueous extract 3 is subjected to extraction with supercritical carbon dioxide 4.

The supercritical CO₂ extraction 4 may be carried out in typical high-pressure vessels known in the art.

Following extraction the supercritical CO₂ and solubilised components are transferred to a separator 4. In the separator, the solvation power of the supercritical fluid is decreased by adjusting the temperature and/or pressure. Generally, an increase in temperature may be used to decrease solvation. Generally, a decrease in pressure may be used to decrease solvation. It is preferred that a decrease in pressure is used to decrease solvation and provide separation of the second extract.

After the CO₂ has been decompressed it may be compressed and returned back to the extraction stage.

The aqueous extract 5 is then concentrated 6. This is achieved by any conventional means, for example by applying thermal energy and/or evaporation under vacuum.

The compounds extracted using supercritical CO₂ extraction (second extract 7) are combined with the concentrated aqueous extract, step 8.

The concentrated aqueous extract 8 is preferably applied to the sheet after the sheet has proceeded through the pressing section, and before the sheet has proceeded through the drying section of the paper-making machine, step 13. The concentrated aqueous extract 8 may be applied to the sheet using spray coating, wetted rollers or any other method suitable in the art. Following this the sheet is dried 14.

The reconstituted tobacco product of the present invention may be used as a tobacco rod, suitable to be ensleeved by a wrapper such as a cigarette paper 15. The reconstituted tobacco product may be shredded to form a tobacco rod. Alternatively, the reconstituted tobacco product may be wrapped or folded to form a tobacco rod 15.

The reconstituted tobacco product of the present invention may also be used as a consumable, or part of a consumable, for an HNB device. It is a reconstituted tobacco product for use in an HNB device.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include,” and variations such as “comprises,” “comprising,” and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example +/−10%. 

1. A method for manufacturing a reconstituted plant material comprising the following steps: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; concentrating the extract to provide a concentrated extract; forming a base sheet from the fibrous portion; providing a pre-mixture by combining a flavouring with a humectant or by combining nicotine with a humectant; combining the pre-mixture with the concentrated extract to provide a modified extract; applying the modified extract to the base sheet.
 2. The method according to claim 1, wherein the solvent is an aqueous solvent.
 3. The method according to claim 1, wherein the fibrous plant material is tobacco.
 4. The method according to claim 3, wherein the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder, and/or tobacco dust.
 5. The method according to claim 1, wherein the flavouring is selected from Mild Menthol, Mixed Berry, Cool Menthol, Peach, Cream Cake, Melon Medley, Apple, Shisha Grape, Virginia Tobacco, and American Red Blend.
 6. The method according to claim 1, wherein the humectant is a polyol.
 7. The method according to claim 6, wherein the polyol is propylene glycol or vegetable glycerine or a combination thereof.
 8. The method according to claim 1, wherein the flavouring or nicotine content of the pre-mixture is within the range 1 to 95 wt % based on the total weight of flavouring or nicotine and humectant.
 9. A reconstituted tobacco product for an HNB device produced by a process according to claim 1, comprising: a humectant; and a flavouring or nicotine; wherein the humectant content is 1 to 50% by weight of the reconstituted tobacco product; and wherein the flavouring or nicotine content is 2 to 25% by weight of the reconstituted tobacco product.
 10. The reconstituted tobacco product according to claim 9, wherein the humectant is a polyol.
 11. The reconstituted tobacco product according to claim 10, wherein the polyol is propylene glycol or vegetable glycerin or combinations thereof.
 12. The reconstituted tobacco product according to claim 9, wherein the flavouring is selected from Mild Menthol, Mixed Berry, Cool Menthol, Peach, Cream Cake, Melon Medley, Apple, Shisha Grape, Virginia Tobacco, and American Red Blend.
 13. The reconstituted tobacco product according to claim 9, wherein the flavouring or nicotine content is 5 to 25 wt % of the reconstituted tobacco product.
 14. The reconstituted tobacco product according to claim 9, wherein the humectant content is 1 to 40 wt % of the reconstituted tobacco product.
 15. Use of the reconstituted tobacco product according to claim 9 in a HNB device.
 16. A method for manufacturing a reconstituted plant material comprising the following steps: extracting a fibrous plant material with a solvent to provide an extract and a fibrous portion; separating the extract from the fibrous portion; forming a base sheet from the fibrous portion; combining a nicotine salt with the extract; applying the extract to the base sheet.
 17. The method according to claim 16, wherein the solvent is an aqueous solvent.
 18. The method according to claim 16, comprising a step of concentrating the extract to provide a concentrated extract, before applying the extract to the base sheet.
 19. The method according to claim 18, wherein the nicotine salt is combined with the concentrated extract.
 20. The method according to claim 16, wherein the fibrous plant material is tobacco.
 21. The method according to claim 20, wherein the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder, and/or tobacco dust.
 22. The method according to claim 16, wherein the nicotine salt is selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof.
 23. The method according to claim 16, wherein the nicotine salt is provided as an aqueous solution.
 24. The method according to claim 23, wherein the aqueous solution of nicotine salt comprises a co-solvent.
 25. A reconstituted tobacco product for an HNB device produced by a process according to claim 16, comprising: a nicotine salt selected from nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and combinations thereof; and wherein the nicotine content is 2 to 25% by weight of the reconstituted tobacco product.
 26. The reconstituted tobacco product according to claim 25, wherein the nicotine content is 5 to 25% by weight of the reconstituted tobacco product.
 27. Use of the reconstituted tobacco product according to claim 25 in a HNB device.
 28. A method for manufacturing a reconstituted plant material comprising the following steps: extracting a fibrous plant material with a liquid solvent to provide a first extract and a fibrous portion; separating the first extract from the fibrous portion; extracting the first extract with supercritical carbon dioxide to provide a second extract; forming a base sheet from the fibrous portion; applying the second extract to the base sheet.
 29. The method according to claim 28, comprising the steps: concentrating the first extract to provide a concentrated extract; and combining the second extract with the concentrated extract before applying the second extract to the base sheet.
 30. The method according to claim 28, wherein the liquid solvent is an aqueous solvent
 31. The method according to claim 28, wherein the fibrous plant material is tobacco.
 32. The method according to claim 31, wherein the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder, and/or tobacco dust.
 33. The method according to claim 28, wherein the supercritical carbon dioxide extraction pressure is within the range 74 to 350 bar.
 34. The method according to claim 28, wherein the supercritical carbon dioxide extraction temperature is within the range 31° C. to 100° C.
 35. The method according to claim 28, wherein the supercritical carbon dioxide contains 1 to 20 mol % of an entrainer.
 36. The method according to claim 28, wherein the supercritical extraction is countercurrent supercritical carbon dioxide extraction. 